By Industrial Print Magazine Staff
Part 3 of 3
Committing to a brand-specific printer lineup can be a frightening decision, but placing trust in one vendor can also be enlightening when it works out. For example, restor3d works with a fleet of over 25 Formlabs 3D printers to create procedure-specific and even patient-specific metal implants and polymer instrumentation.
History of Use
Initially, restor3D focused on 3D printed implants for cervical spine surgeries. During development of the new implants, it kept encountering a challenge in the form of traditionally manufactured stainless steel instrument systems.
“We were developing an innovative implant with features only achievable through 3D printing, but expecting surgeons to use a very traditional instrument system to deliver the implant. So we realized pretty quickly that evolving the instrument offering alongside the implant innovation was going to be an important differentiator for us,” explains Cambre Kelly, CTO, restor3D.
Traditional instrument trays are typically created from stainless steel and cost upwards of $50,000 per tray. At that cost, the trays are an investment, and one that translates to hospitals using the trays for a long time to justify it.
To solve this issue, restor3D leverages its 3D printers, offering both instruments and the accompanying trays at accessible pricing—thanks to the cost effectiveness of AM. The trays and tools are single-use, procedure specific—delivered just in time. Using AM, designs are iterated and reviewed quickly.
Polymer Production
In addition to a lineup of metal 3D printers that allows the company to create tooling and implants in cobalt, chrome, and titanium alloys, it works with Formlabs printers and other polymer machines for the production of polymer parts.
The fleet of Formlabs printers are used for about 90 percent of polymer parts, both single-use instruments and patient-specific customized devices. One specific printer in the group is the Form 4B, which delivers agility and accuracy.
“Sometimes parts break before your ship them. Sometimes you need extra quantities to ship. Sometimes it’s just a straight up redesign from the customer side of things. The accelerated build duration of the Form 4B helps us be much more agile with recovery in these situations,” explains Elena Tercheria, AM manager, restor3D.
In terms of accuracy, Tercheria notes the importance of the time estimate feature on the Form 4B. “While it may seem small, knowing how long a build will take can free up staff for high-value tasks. Just seeing the machine mix every layer and still attain a drastic decrease in the build duration is powerful. That’s a big deal for us, we are able to dependably plan and schedule machine availability in advance.”
The material versatility of the printers is also beneficial. Formlabs offers a library of over 30 materials, including a range of biocompatible materials—popular for healthcare professionals.
Formlabs BioMed Resins are designed for healthcare professionals who seek medical-grade materials for a range of applications where performance and biocompatibility are critical. These materials are developed and manufactured in an ISO 13485-certified facility and are compatible with common disinfection and sterilization methods.
In Summary
Formlabs printers are an ideal solution for restor3d’s thanks to speed, accuracy, ease of use, and range of material options. One additional advantage is the ability to additional printers to its 3D printing fleet over time. The plug-and-play nature of the Formlabs devices allows restor3D to scale on its own terms.
Read part one and two of this series.
Mar2025, Industrial Print Magazine
